PERFORMANCE ENGINE COMPONENTS A History Of Excellence

Since it was formed in 1958 by and the late Keith Duckworth in a small workshop in Acton, , has become the most successful engine manufacturer in the history of . In addition it has achieved enormous success in IndyCars, Champ Cars, rallying, sports cars and touring cars.

The company soon outgrew its little workshop in Acton and moved to north London, where the Ford 105E engine was developed. Cosworth’s first race win followed – at Goodwood in 1960, a Formula Junior win for the young .

By the mid 1960s the company had moved again, to Northampton, and in 1966 a contract was signed with Ford to develop a new three-litre Formula One engine. The legendary DFV was born. Jim Clark again provided the maiden victory, first time out at the Dutch Grand Prix in 1967. The DFV went on to dominate F1 for 15 years with 155 race wins.

In the 1970s the Cosworth DFX ruled the US Indycar scene with an incredible 151 race wins in a 14-year reign, including 10 driver’s championships and 10 Indianapolis 500 victories.

Through the 1980s and ‘90s, Cosworth continued to provide race-winning power with three World Touring Car titles in 1987, ‘93 and ‘94. In Formula 1 the HB engine won 11 races, while in the US Nigel Mansell’s CART championship in 1993 and Jacques Villeneuve’s in 1995 were both powered by Cosworth XBs. In 1994 the Zetec V8 F1 engine took Michael Schumacher to his first world driver’s title. In rallying the Ford Escort Cosworth and the Duratec-R powered Focus WRC gave Ford yet more success.

In 2004 Cosworth still provided the power to 30% of the F1 grid, as well as to the entire Champ Car World Series and the Ford Focus WRC cars. In 2005 Cosworth powered Red Bull’s impressive debut F1 season. In 2006, Cosworth powered the Williams F1 car with a brand new V8 engine which was later acknowledged as the most powerful and highest revving engine on the 2006 grid.

Today, Cosworth continues to enjoy racing success in leading American open wheel series such as Champ Car and Formula Atlantic. The engineering expertise gained over the last 5 decades have enabled Cosworth to launch a broad array of high performance engine components for the aftermarket. With the product range increasing on a continual basis, Cosworth power is now accessible to everyone. A History Of Excellence Contents

Big Valve Cylinder Heads. 5

High Performance Short Block Assemblies. 7

High Performance Long Block Assemblies. 8

Billet Crankshafts. 9

Stroker Engine Kits. 9

Forged Connecting Rods. 10

Ultra High Performance Engine Bearings. 11

Forged Pistons . 12

Performance Ring Sets . 13

High Performance Camshafts. 15

High Performance Head Gaskets. 17

Oil Control / Miscellaneous. 18

Ultra High Performance Head Studs . 20

High Performance Valve Train. 20

Induction / Fuel. 22

Disclaimer. 23

3 Big Valve Cylinder Heads

For over 40 years, Cosworth has offer superior performance for your Each original cylinder head design been the leader in innovative multi high performance engine. is carefully evaluated and tested to valve cylinder head design for establish the improvements required both racing and high performance to meet the target performance level. production cars. The Cosworth CNC Hours of testing and flow bench Ported Big Valve Cylinder head range validation are used to determine is the latest advancement. Modified the best advanced port design from new OE cylinder head castings, yielding maximum usable power substantial gas flow improvements and response. However, there is and upgraded valve train components more to cylinder head design than Nissan VQ35DE just maximum flow. It is critical that port velocity is maintained CNC Ported Big Valve Cylinder Heads to ensure drivability and valve Part No. Application Specification train components are matched to KK3670 Subaru WRX STI EJ25 (2.5L) Pair 2004-2006 guarantee reliable performance. KK3671 Nissan VQ35 (3.5L) Pair 2002-2005

KK3918 Nissan VQ35 (3.5L) Pair 2006 “Rev Up” version Once all of these factors have

KK3672 Mitsubishi Evo VII-VIII 4G63 (2.0L) 2000-2005 been tested and validated, the final KK3852 Mitsubishi Evo IX 4G63 (2.0L) 2006 MIVEC port contour is digitized. Using the KK3673 BMW MINI Cooper/Cooper S (1.6L) digitized program, we then reshape 20001699 Subaru WRX STI EJ25 (2.5L) Pair 2007 both intake and exhaust ports 20000691 Ford Duratec, 2.0L/2.3L using a 5 axis CNC mill producing 20000704 Mazda MZR, 2.0L/2.3L an accurate and consistent port shape every time. In addition to re- CNC Ported Big Valve Cylinder Heads with Camshafts shaping and enlarging the intake

Part No. Application Specification and exhaust ports, most Big Valve

Pair with KK3766 Camshafts and valve lash set Cylinder heads feature a re-shaped SB8010 Subaru WRX STI EJ25 (2.5L) with cam bucket (USA) combustion chamber to un-shroud Pair with KK3920 Camshafts and valve lash set SB8012 Subaru WRX STI EJ25 (2.5L) with cam bucket (Japan/Euro) the valves increasing air flow and 20002024 Subaru WRX STI EJ25 (2.5L) Pair 2007 with KK3766 Camshafts (USA) performance. After machining, each 20002026 Subaru WRX STI EJ25 (2.5L) Pair 2007 with KK3920 Camshafts (Japan/Euro) cylinder head receives a multi- angle high performance valve job on our precision CNC valve seat cutter. Then each cylinder head is ultrasonically cleaned, serialized and finally hand assembled with select high performance valve train components, ready to install on your engine.

Mitsubishi 4G63 Subaru EJ25

4 Big Valve Cylinder Heads

Key Features:

„„ All new OE Castings „„ Enlarged intake and exhaust ports „„ Large diameter stainless steel intake valves „„ Large diameter inconel exhaust valves „„ Hi-rev, dual valve springs „„ Titanium retainers „„ Hardened steel spring platforms „„ Reshaped combustion chamber on most applications „„ Flow bench proven design „„ Dynamometer tested „„ Machined Cosworth logo „„ Precision multi-angle valve job „„ Pre-assembled, ready to install „„ Machined port bore finish „„ Knife edge port divider Cylinder head development

CNC Valve seat cutter

5 High Performance Short Block Assemblies

Cosworth high performance engine forged crankshaft or Cosworth billet assemblies are the perfect basis for crank along with Cosworth forged your high performance application. connecting rods, Cosworth tri-metal Each version has gone through bearings and Cosworth forged countless hours of engineering pistons. The motorsport grade parts and evaluation to determine the are then professionally assembled best combination of parts and build by expert engine builders in the specification, ensuring maximum Cosworth engine assembly facility. reliable performance. Each Each high performance engine Cosworth high performance engine assembly includes a complete assembly starts with all new select specification sheet listing all critical components as the foundation of dimensions along with a serialized the performance build. Every block plaque. For maximum performance, is thoroughly inspected before the combine with a Cosworth CNC cylinders are honed to perfection. We ported Big Valve Cylinder Head and then balance the rotating assembly camshaft set. that includes either a new factory

High Performance Short Blocks

Part No. Application Specification

SB8005 Subaru STI EJ25 Short Block (2.5L) Forged Pistons, Rods

SB8007 Subaru STI EJ25 Short Block (2.5L) Forged Pistons, Rods with 79mm Billet Crank

20000067 Nissan VQ35 Short Block (3.5L) Lo comp 8.8:1

KK3879 Nissan VQ35 Short Block (3.5L) Hi comp 11:1 Mitsubishi Evo VIII/IX 4G63 Short Block CI8015 Forged Pistons, Rods (2.0L) Mitsubishi Evo VII/IX 4G63 Short Block CI8018 Forged Pistons, Rods with 94mm Billet Crank (2.2L)

Subaru EJ25 High Performance Short Block 2.5L

The Cosworth EJ25 is an excellent starting point for high performance and track day applications.

„„ New Subaru EJ25 STI EJ257 „„ Cosworth Tri-metal bearings Block „„ Balanced to within 0.5 gram „„ New Subaru EJ25 STI Forged „„ Complete blue-printed assembly Crankshaft or Cosworth Billet „„ Ring gap set Crank (79mm) „„ Bearing clearance checked „„ Cosworth Forged H-beam „„ Deck height checked connecting rods „„ Connecting Rod side clearance „„ Cosworth Forged Pistons checked (99.5mm) and rings „„ Crankshaft end float checked

6 High Performance Short Block Assemblies

Mitsubishi 4G63 (Evolution VII-IX) High Performance Short Block 2.0L

The Cosworth 2.0L 4G63 is an excellent starting point for high performance and track day applications.

„„ New Mitsubishi 4G63 Evolution „„ Piston squirt jets Block „„ Balanced to within 0.5 gram „„ New Mitsubishi forged crankshaft „„ Complete blue-printed assembly (88mm) „„ Ring gap set „„ Cosworth Forged H-beam „„ Bearing clearance checked connecting rods „„ Deck height checked „„ Cosworth Forged Pistons „„ Connecting Rod side clearance (85mm) and rings checked „„ Cosworth Tri-metal bearings „„ Crankshaft end float checked „„ Cosworth Heavy Duty main studs

Mitsubishi 4G63 (Evolution VII-IX) High Performance Short Block 2.2L

The Cosworth 4G63 2.2L stroker engine combines the perfect bore to stroke ratio, yielding potentially big gains in torque while still allowing the engine to rotate and produce power at higher RPMs.

„„ New Mitsubishi 4G63 Evolution „„ Piston squirt jets High Performance Short Blocks Block „„ Balanced to within 0.5 gram

Part No. Application Specification „„ New Cosworth Billet Crank „„ Complete blue-printed assembly „„ SB8005 Subaru STI EJ25 Short Block (2.5L) Forged Pistons, Rods (94mm) Ring gap set „„ „„ SB8007 Subaru STI EJ25 Short Block (2.5L) Forged Pistons, Rods with 79mm Billet Crank Cosworth Forged H-beam Bearing clearance checked „„ 20000067 Nissan VQ35 Short Block (3.5L) Lo comp 8.8:1 connecting rods Deck height checked „„ Cosworth Forged Pistons „„ Connecting Rod side clearance KK3879 Nissan VQ35 Short Block (3.5L) Hi comp 11:1 Mitsubishi Evo VIII/IX 4G63 Short Block (86mm) and rings checked CI8015 Forged Pistons, Rods (2.0L) „„ Cosworth Tri-metal bearings „„ Crankshaft end float checked Mitsubishi Evo VII/IX 4G63 Short Block CI8018 Forged Pistons, Rods with 94mm Billet Crank „„ Cosworth Heavy Duty main studs (2.2L)

Nissan VQ35DE (350Z-G35) High Performance Short Block 3.5L

The Cosworth VQ35DE high performance short block is the perfect foundation for your high performance application. Available in either high compression 11:1 or low compression 8.8:1 for turbo or supercharged applications.

„„ New Nissan forged crankshaft „„ Balanced to within 0.5 gram (81.4mm) „„ Complete blue-printed assembly „„ Cosworth Forged H-beam „„ Ring gap set connecting rods „„ Bearing clearance checked „„ Cosworth Forged Pistons „„ Deck height checked (95.5mm) and rings „„ Connecting Rod side clearance „„ Cosworth Tri-metal bearings checked „„ Cosworth Heavy Duty main studs „„ Crankshaft end float checked „„ Piston squirt jets

7 High Performance Long Block Assemblies

The Cosworth Subaru EJ25 CS600 wall clearance. The block is then valve lash set to our specifications. series is designed for extreme assembled with our Forged Pistons, The cylinder heads are secured with track day use and the demanding motorsport grade Forged H-Beam our high performance 11mm steel performance enthusiast. Each connecting rods along with our high studs and sealed with a Cosworth assembly is precision built by one of performance rod and main bearings high performance stopper layer steel Cosworth’s skilled craftsmen using and a new STI forged crankshaft. head gasket. Finally, we install one the finest components from our For maximum performance, an of our blue-printed, high pressure oil parts catalogue to ensure maximum optional steel billet crank is available pumps for maximum lubrication. This reliable power and performance. (CS600X). Once the cylinder block proven engine combination has been Starting with a new Subaru EJ257 assembly is completed, we install a used by top teams to win events in semi closed deck block, we pair of our CNC machine port-bored both North America and Europe. meticulously hone each bore to Big Valve Cylinder heads with our guarantee perfect piston to cylinder proven “S2” camshafts complete with Features

„„ New Subaru EJ25 STI Engine case „„ New Subaru EJ25 STI Forged Crankshaft „„ Optional Cosworth Billet Crankshaft (CS600X) „„ Cosworth forged H-beam Connecting rods „„ Cosworth Forged Pistons and rings „„ Cosworth motorsport Tri-metal USA/North American specification bearings Part No. Application Specification „„ Balanced to within 0.5 gram 2004-2006 with Big Valve Cylinder heads and KK3766 20000162 Subaru EJ25 (2.5L) „„ Camshafts - Billet Crankshaft Complete blue-printed assembly 2004-2006 with Big Valve Cylinder heads and KK3766 „„ Enlarged intake and exhaust 20000161 Subaru EJ25 (2.5L) Camshafts - STD Crankshaft ports 2007 with Big Valve Cylinder heads and KK3766 20002503 Subaru EJ25 (2.5L) „„ Camshafts - Billet Crankshaft Large diameter stainless steel 2007 with Big Valve Cylinder heads and KK3766 intake valves 20002504 Subaru EJ25 (2.5L) Camshafts - STD Crankshaft „„ Large diameter inconel exhaust valves „„ Hi-rev, dual valve springs European and Japanese specification „„ Titanium retainers Part No. Application Specification „„ Hardened steel spring platforms 2004-2006 with Big Valve Cylinder heads and KK3920 20000160 Subaru EJ25 (2.5L) „„ Multi angle valve job Camshafts - Billet Crankshaft „„ CNC machined port finish 2004-2006 with Big Valve Cylinder heads and KK3920 SB8008 Subaru EJ25 (2.5L) Camshafts - STD Crankshaft „„ Knife edge port divider 2007 with Big Valve Cylinder heads and KK3920 20002505 Subaru EJ25 (2.5L) „„ Cosworth S2 High lift camshafts Camshafts - Billet Crankshaft „„ Valve lash set 2007 with Big Valve Cylinder heads and KK3920 20002506 Subaru EJ25 (2.5L) Camshafts - STD Crankshaft „„ Cosworth high pressure oil pump „„ Cam covers Includes engine assembly with cylinder heads, camshafts, oil pump and cam covers „„ Cosworth serial number

8 High Performance Long Block Assemblies Billet Crankshafts

Increased engine performance often to endure the harshest conditions means increased engine speed and and have been tested to withstand load. Original factory crankshafts over 1,000HP. may not be able to withstand Features Include: the added stress, resulting in „„ Superior lubrication catastrophic failure. Cosworth billet „„ Profiled counterweights crankshafts are machined from ultra „„ High strength Subaru EJ25 strong EN40B steel, are engineered „„ Light weight

Billet Crankshafts

Part No. Application Specification

PR7863 Mitsubishi EVO 4G63 (2.2L conversion) 94mm stroke - Fully counterweighted \ Billet Steel

20001414 Subaru WRX STI EJ25 (2.5L) 79mm stroke - Light weight version \ Billet Steel

20001546 Subaru WRX STI EJ25 (2.5L) 81mm stroke - Light weight version \ Billet Steel Mitsubishi 4G63

Stroker Engine Kits

Cosworth stroker kits are the perfect Stroker Kits way to add displacement, torque Part No. Application and power to your engine. Each kit KK3831 Mitsubishi Evo 4G63 (2.2L)

includes select matched components 20002500 Subaru EJ25 (2.6L) from our parts list ensuring reliable Subaru EJ20 (2.2L) forged 20002501 (79mm stroke) Crank performance. Subaru EJ20 (2.2L) Billet 20002502 (79mm stroke) Crank Mitsubishi 4G63 (Evolution VII-IX) 2.2L Subaru EJ25 2.6L

„„ Cosworth Forged Pistons (86mm) „„ Cosworth Fully Counterweighted Billet Crankshaft (94mm) „„ Forged Cosworth Connecting Rods „„ Cosworth Rod and Main Bearings „„ Cosworth Piston Rings

Subaru EJ25 2.6L

„„ Cosworth Forged Pistons (99.5mm) „„ Cosworth Fully Counterweighted Billet Crankshaft (81mm) „„ Forged Cosworth Connecting Rods „„ Cosworth Rod and Main Bearings „„ Cosworth Piston Rings Mitsubishi 4G63 2.2L

9 Forged Connecting Rods

The connecting rod is the vital link 4340 (EN24) steel and machined to between the piston and power. When exacting tolerances. engine output is increased, the Features Include: demands placed on the connecting „„ Strong, light weight H-beam rod increase as well. To ensure engine design reliability in all conditions, original „„ Heavy duty rod bolt (260,000psi) connecting rods should be replaced „„ Manufactured from 4340 (EN24) with heavy duty specification parts. steel Cosworth Forged Connecting Rods „„ Small end bushed for floating pin are manufactured from high strength

Forged Connecting Rods

Part No. Application Specification

20002587 Subaru WRX STI EJ25 (2.5L) set of four H-Beam

20002587 Subaru WRX EJ20 (2.0L) set of four H-Beam

20002632 Mitsubishi Evo 4G63 (2.0L) set of four H-Beam

20002585 Nissan VQ35 (3.5L) set of six H-Beam

20002588 Nissan RB26 (2.6L) set of six H-Beam

20002589 Nissan SR20 (2.0L) set of four H-Beam

10 Forged Connecting Rods Ultra High Performance Engine Bearings

Engine bearings are one of the Engineered with the following „„ 3/4 grooving on Main Bearings most vital components within an features: providing optimum oil supply „„ Tight consistent wall tolerances engine and are often overlooked „„ High strength overlay plate with „„ Oversize chamfers where when considering high performance reduced thickness for better oil applicable upgrades. Performance engineered, control and less friction „„ Flash plating eliminated for „„ Hardened steel backing on all multi-layer bearings generate less improved heat transfer connecting rod bearings heat than normal bearings by reducing „„ Tested to over 1000 horsepower! „„ Increased crush for better friction. Cosworth race bearing sets retention feature unique combinations of design, metallurgy and engineering High Performance Engine Bearings to deliver performance in extreme conditions. Cosworth Race bearings Part No. Application Specification sets are available in two sizes to PR7940 Subaru WRX/STI EJ25/ EJ20 Main Bearing Set - Tri Metal Size 1 PR7889 Subaru WRX/STIEJ25/ EJ20 Rod Bearing Set - Tri Metal Size 1 accommodate most applications. SB0006 Subaru WRX/ STI EJ25/EJ20 Main Bearing Set - Tri Metal Size 2 Size “1” bearings are a nominal SB0007 Subaru WRX/STI EJ25/EJ20 Rod Bearing Set - Tri Metal Size 2

standard size and are used for most PR7894 Mitsubishi Evo 4G63 (2.0L) Main Bearing Set - Tri Metal Size 1

applications. Size “2” bearings PR7893 Mitsubishi Evo 4G63 (2.0L) Rod Bearing Set - Tri Metal Size 1 feature an additional .001” clearance PR7427 Mitsubishi Evo 4G63 (2.0L) Main Bearing Set - Tri Metal Size 2 and should be used when extra PR7428 Mitsubishi Evo 4G63 (2.0L) Rod Bearing Set - Tri Metal Size 2 clearance is required. PR7429 Mitsubishi Evo 4G63 (2.0L) Thrust Bearing set PR7911 Nissan VQ35 (3.5L) Main Bearing Set - Tri Metal Size 1

PR7910 Nissan VQ35 (3.5L) Rod Bearing Set - Tri Metal Size 1

PR7853 Nissan VQ35 (3.5L) Main Bearing Set - Tri Metal Size 2

PR7854 Nissan VQ35 (3.5L) Rod Bearing Set - Tri Metal Size 2

PR7859 Nissan VQ35 (3.5L) Thrust Bearing Set

PR7896 Nissan SR20 (2.0L) Main Bearing Set - Tri Metal Size 1

PR7895 Nissan SR20 (2.0L) Rod Bearing Set - Tri Metal Size 1

PR7851 Nissan SR20 (2.0L) Main Bearing Set - Tri Metal Size 2

PR7852 Nissan SR20 (2.0L) Rod Bearing Set - Tri Metal Size 2

PR7937 Nissan SR20 (2.0L) Thrust Bearing Set

PR7892 Nissan RB25/26 Main Bearing Set - Tri Metal Size 1

PR7891 Nissan RB25/26 Rod Bearing Set - Tri Metal Size 1

PR7655 Nissan RB25/26 Main Bearing Set - Tri Metal Size 2

PR7656 Nissan RB25/26 Rod Bearing Set - Tri Metal Size 2

Specification: Size 1 = nominal standard clearance, Size 2 = .001” extra clearance

11 Forged Pistons

The piston is one of the most pistons are manufactured using the Features Include: important components within the same methods as our Formula One „„ Unique forgings for each engine. It can be subjected to pistons and include features such as application directional change up to 285 times anti-scuff skirt coating, ultra-strong „„ ‘Xylan’ anti scuff skirt coating every second and must withstand pins, polished top and patented anti- „„ Polished tops (reduces carbon acceleration forces of 8500g’s. detonation bands. Additionally, each build up and relieves stress) „„ Manufactured from proprietary Cosworth high performance forged application uses a unique forging alloy (CosAl 010) pistons are designed and engineered to minimize weight and ensure the „„ Ultra strong pin to withstand this type of punishment strongest possible piston design. „„ Patented anti-detonation bands and still perform. All Cosworth

Nissan VQ35 High Compression

Forged Piston Sets (Includes pistons, pins and circlips)

Part No. Application

20000897 Subaru WRX STI EJ25 (2.5L) 99.5mm 8.2:1cr comes with pins & clips

20000898 Subaru WRX STI EJ25 (2.5L) 99.75mm 8.2:1cr comes with pins & clips

20000899 Subaru WRX STI EJ25 (2.5L) 100.mm 8.2:1cr comes with pins & clips

20002111 Subaru WRX EJ20 (2.0L) 92mm 8.0:1cr

20002112 Subaru WRX EJ20 (2.0L) 92.5mm 8.0:1cr

20002113 Subaru WRX EJ20 (2.0L) 93mm 8.0:1cr

20002431 Subaru EJ257 (81mm stroker) STD

20002432 Subaru EJ257 (81mm stroker) +0.25mm

20002433 Subaru EJ257 (81mm stroker) +0.50mm

20002489 Subaru EJ20 (79mm stroker) STD

20002490 Subaru EJ20 (79mm stroker) +0.25mm

20002491 Subaru EJ20 (79mm stroker) +0.50mm

20003223 Nissan VQ35 (3.5L) High CR 95.5mm 11.0:1cr (3 x Left Hand & 3 x Right Hand)

20003224 Nissan VQ35 (3.5L) High CR 95.75mm 11.0:1cr (3 x Left Hand & 3 x Right Hand)

20003225 Nissan VQ35 (3.5L) High CR 96.mm 11.0:1cr (3 x Left Hand & 3 x Right Hand)

20002132 Nissan VQ35 (3.5L) Low CR 95.5mm 8.8:1cr (Turbo application)

20002133 Nissan VQ35 (3.5L) Low CR 96mm 8.8:1cr (Turbo application)

20002134 Nissan VQ35 (3.5L) Low CR 96.5mm 8.8:1cr (Turbo application)

20000832 Mitsubishi Evo IV-IX 4G63 (2.0L) 85mm 8.8:1cr (comes with pins & clips)

20000833 Mitsubishi Evo IV-IX 4G63 (2.0L) 85.50mm 8.8:1cr (comes with pins & clips)

20000834 Mitsubishi Evo IV-IX 4G63 (2.0L) 86mm 8.8:1cr (comes with pins & clips)

20000971 Mitsubishi Evo IV-IX 4G63 (2.2L) 86mm 8.8:1cr (For use with 94mm crank)

12 Forged Pistons Performance Ring Sets

Performance Ring Sets for Cosworth Pistons

Part No. Application Specification

20001515 Subaru WRX STI EJ25 (2.5L) 99.5mm

20001516 Subaru WRX STI EJ25 (2.5L) 99.75mm

20001517 Subaru WRX STI EJ25 (2.5L) 100mm

PR7320 Subaru WRX EJ20 (2.0L) 92mm

PR7321 Subaru WRX EJ20 (2.0L) 92.5mm

20001512 Nissan VQ35 (3.5L) 95.5mm

20001514 Nissan VQ35 (3.5L) 96.mm

PR7317 Mitsubishi Evo 4G63 (2.0L) 85mm

20002246 Mitsubishi Evo 4G63 (2.0L) 86mm

Cosworth Tech: Green Pistons Xylan is a fluorpolymer coating designed for use on various engine components and fasteners. Cosworth pistons use Xylan coating to provide lubrication and control friction, wear resistance, heat resistance, nonstick and release properties and, at the same time, can also protect from corrosion. This is the same coating we use on many of our ultra-high performance race engines.

Mitsubishi 4G63 Subaru EJ25

13 High Performance Camshafts

Cosworth has been engineering Performance Camshafts camshafts for nearly 50 years. That Part No. Application Specification coupled with years of innovative Subaru WRX STI EJ25 (2.5L) Set of four Int.”260” deg. 9.6mm lift / Exh. “260” deg. KK3814 multi valve cylinder head design (AVCS Type) North American spec 9.6mm lift Subaru WRX STI EJ25 (2.5L) Set of four Int.”278” deg. 10.7mm lift / Exh. “274” deg. KK3766 ensures our camshaft designs (AVCS Type) North American spec S2 Grind 10.mm lift are the most efficient in providing KK3765 Subaru WRX EJ20 (2.0L) Set of four “272” deg. 10mm lift Subaru WRX STI EJ25/EJ20 Set of four Int.”278” deg. 10.7mm lift / Exh. “274” deg. maximum usable power across the KK3920 (AVCS Type) Japan / European spec S2 Grind 10.mm lift widest power band. Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1 KK3805 “264” deg. 10.2 mm lift exhaust cam) M1 Grind Each cam is ground from a Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1 KK3806 “272” deg. 11 mm lift new billet and finished using exhaust cam) M2 Grind Mitsubishi Evo IX 4G63 (2.0L) Pr (1 intake KK3921 MIVEC Intake/Exhaust “272” deg. 11 mm lift the same procedures we use in and 1 exhaust cam) M2 Grind Mitsubishi Evo IX 4G63 (2.0L) Pr (1 intake MIVEC Intake “280” deg. 11.6mm lift / our extreme level race engines. 20002517 and 1 exhaust cam) M3 Grind Exhaust “272” deg. 11 mm lift Cosworth camshafts are the perfect Mitsubishi Evo 4G63 (2.0L) Intake cam only PR7832 “264” deg. 10.2 mm lift compliment to our CNC Ported Big M1 Grind Mitsubishi Evo 4G63 (2.0L) Exhaust cam only PR7833 “264” deg. 10.2 mm lift Valve Cylinder Heads. Our cams are M1 Grind Mitsubishi Evo 4G63 (2.0L) Intake cam only profiled to increase boost response PR7834 “272” deg. 11 mm lift M2 Grind thereby increasing engine torque Mitsubishi Evo 4G63 (2.0L) Exhaust cam only PR7835 “272” deg. 11 mm lift and power and are fully compatible M2 Grind with our CNC Ported Big Valve Cylinder Heads.

Cosworth Tech - Subaru Cams Our Subaru AVCS cams are available for both North American and Japanese/ European applications. While cam profiles are the same, cam angle triggers are significantly different. AVCS camshafts for North American applications use a series of three slots to activate the cam angle sensor. Japanese/European applications rely on four raised triggers to activate the sensor. If in doubt, check your original North American Japanese/European cams before ordering.

14 High Performance Camshafts

Performance Camshafts Features Include:

Part No. Application Specification „„ Ground from new billets „„ Subaru WRX STI EJ25 (2.5L) Set of four Int.”260” deg. 9.6mm lift / Exh. “260” deg. Engineered and tested profiles KK3814 (AVCS Type) North American spec 9.6mm lift „„ Broad power band Subaru WRX STI EJ25 (2.5L) Set of four Int.”278” deg. 10.7mm lift / Exh. “274” deg. KK3766 „„ Compatible with Cosworth CNC (AVCS Type) North American spec S2 Grind 10.mm lift ported Big Valve Cylinder Heads KK3765 Subaru WRX EJ20 (2.0L) Set of four “272” deg. 10mm lift Subaru WRX STI EJ25/EJ20 Set of four Int.”278” deg. 10.7mm lift / Exh. “274” deg. KK3920 (AVCS Type) Japan / European spec S2 Grind 10.mm lift Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1 KK3805 “264” deg. 10.2 mm lift exhaust cam) M1 Grind Mitsubishi Evo 4G63 (2.0L) Pr (1 intake and 1 KK3806 “272” deg. 11 mm lift exhaust cam) M2 Grind Mitsubishi Evo IX 4G63 (2.0L) Pr (1 intake KK3921 MIVEC Intake/Exhaust “272” deg. 11 mm lift and 1 exhaust cam) M2 Grind Mitsubishi Evo IX 4G63 (2.0L) Pr (1 intake MIVEC Intake “280” deg. 11.6mm lift / 20002517 and 1 exhaust cam) M3 Grind Exhaust “272” deg. 11 mm lift Subaru AVCS Mitsubishi Evo 4G63 (2.0L) Intake cam only PR7832 “264” deg. 10.2 mm lift M1 Grind Mitsubishi Evo 4G63 (2.0L) Exhaust cam only PR7833 “264” deg. 10.2 mm lift M1 Grind Mitsubishi Evo 4G63 (2.0L) Intake cam only PR7834 “272” deg. 11 mm lift M2 Grind Mitsubishi Evo 4G63 (2.0L) Exhaust cam only PR7835 “272” deg. 11 mm lift M2 Grind

Mitsubishi Evo 4G63

Mitsubishi EVO 4G63 Mivec

15 High Performance Head Gaskets

Cosworth High Performance are manufactured from pre-coated Each gasket is carefully engineered Head Gaskets are engineered die cut stainless steel resulting in with the following features: to seal in power under the most uniform coating distribution and „„ Individual die cut layers of demanding conditions. Constructed consistent shape. stainless steel with superior from stainless steel with a folded consistency compared to laser stopper layer, each application cut gaskets „„ Pre-coated stainless steel with a features superior sealing compared Gasket Layer 0.25 micron layer of nitrile rubber to conventional multi layer steel Folded Stopper Layer ensures consistent distribution of gaskets. Additionally, Cosworth coating with no high or low areas Gasket Layer High Performance Head Gaskets „„ Manufacturing dimensional tolerance of +/- 0.001” „„ Die cut manufacturing process ensures smooth edges, unlike laser cut gaskets „„ Cosworth gaskets feature a “folded stopper” layer for additional clamping force around each cylinder. The width of sealing area is specific for each application thereby providing Without folded stopper layer, clamping force is Folded stopper layer provides complete sealing ultimate sealing properties limited resulting in incomplete sealing around around entire combustion chamber combustion chamber „„ Available in a range of thicknesses for specific High Performance Head Gaskets applications

Part No. Application Specification

20000900 Nissan VQ35DE (3.5L) Bore = 96mm T ~ 0.6mm (Pair)

20000903 Nissan VQ35DE (3.5L) Bore = 98mm T ~ 0.6mm (Pair)

20000924 Nissan SR20DET (2.0L) Bore = 87mm T ~ 1.1mm

20000925 Nissan SR20DET (2.0L) Bore = 87mm T ~ 1.5mm

20000926 Nissan SR20DET (2.0L) Bore = 87mm T ~ 1.8mm

20000927 Nissan RB26DETT (2.6L) Bore = 87mm T ~ 1.5mm

20000928 Nissan RB26DETT (2.6L) Bore = 87mm T ~ 1.5mm

20000929 Nissan RB26DETT (2.6L) Bore = 87mm T ~ 1.8mm

20000930 Nissan RB25DET (2.5L) Bore = 87mm T ~ 1.1mm

20000931 Nissan RB25DET (2.5L) Bore = 87mm T ~ 1.5mm Nissan VQ35DE 20001689 Mitsubishi Evo IX 4G63 (2.0L) Bore = 86mm T ~ 1.3mm

20001690 Mitsubishi Evo IX 4G63 (2.0L) Bore = 86mm T ~ 1.5mm

20000909 Mitsubishi Evo IV-VIII 4G63 (2.0L) Bore = 86mm T ~ 1.3mm

20000910 Mitsubishi Evo IV-VIII 4G63 (2.0L) Bore = 86mm T ~ 1.5mm

20000913 Subaru WRX STI EJ25 (2.5L) Bore = 101mm T ~ 0.78mm each

20000916 Subaru WRX STI EJ25 (2.5L) Bore = 101mm T ~ 1.1mm each

20002145 Subaru WRX STI EJ25 (2.5L) Bore = 101mm T ~ 1.5mm each

20000919 Subaru WRX EJ20 (2.0L) Bore = 93mm T ~ 0.78mm each

20000922 Subaru WRX EJ20 (2.0L) Bore = 93mm T ~ 1.1mm each Mitsubishi 4G63

16 High Performance Head Gaskets

Stopper Sealing Layer

Uniform Nitrile Rubber Coating

Die Cut Edges

Subaru EJ25

17 Oil Control / Miscellaneous

High performance engines reject a heat and stabilize oil temperatures. substantial amount of heat through the Cosworth oil control components oil system. Maintaining oil pressure are engineered to combat several and control along with an increase problem areas experienced in high in actual volume will help dissipate performance engines.

Subaru Billet Timing Belt Guide - Part number SB0001

The original sheet metal timing belt guide can flex from belt deflection when subjected to extreme RPM causing the timing belt to skip one or more teeth on the crankshaft sprocket. The Cosworth Billet Timing Belt Guide was developed to control this problem and is machined from solid aluminium with a hard anodized finish. Includes mounting hardware.

Subaru Billet Cam Angle Sensor Bracket - Part number SB0002

Used for mounting the cam angle sensor to the front of Non North American Spec STI cylinder heads. Useful for adapting our cylinder heads to Japanese and European market engines.

Subaru Oil Pan Baffle - Part number 20002499

Oil control can be a problem with high performance and high revving Subaru engines. High crankcase pressure along with the horizontal engine platform restricts rapid oil return from the cylinder heads to the oil pan. Pressure builds in the heads and crankcase causing massive blow by and power loss. The Cosworth Subaru Oil Pan Baffle has been engineered with diverters to control oil returning from the cylinder heads to the pan directing it away from the crankshaft. Additionally, one-way valves prevent oil from re-entering the upper crankcase chamber thereby limiting blow by and preventing oil starvation during hard driving. Manufactured from stainless steel and installs easily between the block and oil pan on both EJ20/EJ25 series engines. Use with our High Volume Oil Pan for maximum oil control.

Subaru EJ20/25 High Volume Oil Pan - Part number 20001238

Sustained high RPM or prolonged high speed driving will result in elevated oil temperatures. Additional oil volume along with improved oil control will reduce damaging oil temperatures. The Cosworth EJ20/EJ25 High Volume Oil Pan is fabricated from both custom and original components resulting in an additional 2qts oil capacity when compared to standard oil pan. Each kit includes powder coated oil pan, mounting hardware, oil pickup and spacer. Will not work with some equal length exhaust manifolds.

18 Oil Control / Miscellaneous Oil Control Part No. Application

SB0001 Subaru (EJ20/EJ25) Billet Timing Belt Guide

SB0002 Subaru Billet Cam Angle Sensor Bracket (for mounting cam angle sensor on front of head)

KK3928 Subaru (EJ20/EJ25) Blueprinted Oil Pump with high pressure mod & install kit

20001185 Subaru (EJ20/EJ25) High Volume/Pressure Blueprinted Oil Pump & install kit

20001238 Subaru (EJ20/EJ25) High Volume Oil Pan

20002499 Subaru (EJ20/EJ25) Oil Control Baffle

20001382 Mitsubishi Evo VII-IX 4G63 (2.0L) Crankshaft Oil Scraper

Mitsubishi 4G63 Crankscraper - to main bearing girdle. Designed Part number 20001382 from 2.6 mm (12gauge) steel plate and includes required mounting The Cosworth 4G63 Crankscraper hardware. is engineered to reduce parasitic drag on the crankshaft caused by oil accumulation that surrounds the crankshaft during rotation. This oil buildup causes additional drag and can reduce power output. Additionally, overall oil control is improved by keeping oil in the sump. Especially useful in high rpm and race applications. Mounts

Subaru EJ20/25 Oil pump - High Pressure - Part number KK3928

High performance engines require additional oil pressure because of the increased demand placed upon various components within the engine. The Cosworth High Pressure Subaru EJ20/EJ25 series oil pump is modified to increase oil pressure helping to ensure superior lubrication. Each pump is carefully inspected and de- burred for unobstructed oil flow. Perfect for high performance daily use Each kit includes all required mounting hardware and seals.

Subaru EJ20/25 Oil pump - High 20%. Suggested applications include Volume - Part number 20001185 drag, track day and race use. Each kit includes all required mounting Increasing oil volume will help to hardware and seals. prevent bearing damage and engine failure. Additionally, sustained High RPM use may cause oil starvation at the rod and main bearings. The Cosworth High Volume Subaru EJ20/EJ25 series oil pump utilizes a completely new inner and outer 12mm rotor to increase volume by Pump Gear: 10mm vs 12mm

19 Ultra High Performance Head Studs

Essential for high performance and come complete with nuts and High Performance Head Stud Kits engine builds, heavy duty head studs washers. Manufactured with hex Part No. Application reduce cylinder head movement broach end for ease of installation. Subaru WRX STI EJ25/EJ20 20002440 in high boost or high compression (2.5L) 11mm Subaru WRX STI EJ25/EJ20 engines optimizing cylinder head 20002439 (2.5L) 14mm (extensive block to block sealing. Cosworth Ultra machining required) 20002441 Nissan VQ35 (3.5L) 11mm High Performance Head Studs are 20002442 Mitsubishi Evo 4G63 (2.0L) 11mm manufactured from H11 tool steel 20002443 Nissan RB26DETT (2.6L) 11mm with 260,000psi tensile strength 20002444 Nissan SR20DET (2.0L) 12mm

High Performance Valve Train

High Performance Valves produced from high quality stainless back for improved air flow and dished steel for maximum durability. Exhaust face for additional weight reduction. Large diameter valves are essential valves are machined from Inconel for Cosworth high performance valves for improved air flow. Cosworth high temperature (2400° F) reliability. are compatible with Cosworth Ultra high performance intake valves are Each valve features swirl polished Race Valve Spring Kits.

Performance Valves

Part No. Application

PR7559 Valve, Inlet +1.0mm Subaru EJ25 - Stainless Steel (37.0mm)

PR7558 Valve, EX +1.0mm Subaru EJ25 - Inconel (33.0mm)

PR7500 Valve, Inlet +1.0mm Mitsubishi 4G63 - Stainless Steel (35.0mm)

PR7501 Valve, Ex +1.0mm Mitsubishi 4G63 - Inconel (31.5mm)

PR7602 Valve, Inlet +1.0mm Nissan VQ35 - Stainless Steel (38.15mm)

PR7603 Valve, Ex +1.0mm Nissan VQ35 - Inconel (32.35mm)

Ultra Race Valve Spring Kits with matched lightweight titanium heat treated and stress relieved retainers, keepers, and hardened for long term reliability. Ultra Race Cosworth Ultra Race Valve Spring steel spring seats. Cosworth Ultra Valve Spring kits are compatible with Kits are engineered for use in Race Valve Springs are wound from Cosworth high performance valves. situations that require valve control the highest quality chrome silicone in extreme conditions. Each kit steel with chamfered ends and are consists of dual valve springs

Ultra-High RPM Valve Spring Sets

Part No. Application

KK3813 Mitsubishi Evo 4G63 (2.0L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set

KK3839 Subaru EJ25 STI (2.5L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set

20002550 Nissan VQ35 (3.5L) Ultra-High RPM Dual Valve Spring / Titanium Retainer set

20 High RPM Valve Springs capability for optimum performance Ultra High Performance Head Studs potential and improved valve Cosworth High RPM Valve Springs control. Single spring design allows are the result of countless hours of easy installation with no machining *Seal clearance engineering, testing and validation High Performance Head Stud Kits required and is perfect for typical Install Height ensuring the best possible spring “F1” high performance use. Part No. Application for high performance applications. Subaru WRX STI EJ25/EJ20 20002440 (2.5L) 11mm Cosworth High RPM Valve Springs

Subaru WRX STI EJ25/EJ20 are wound from the world’s finest „„ Manufactured from the finest 20002439 (2.5L) 14mm (extensive block machining required) Japanese Kobe steel and feature Japanese Kobe steel 20002441 Nissan VQ35 (3.5L) 11mm dual chamfered ends to reduce wear „„ Single spring design for easy 20002442 Mitsubishi Evo 4G63 (2.0L) 11mm on seats and retainers. Each spring installation 20002443 Nissan RB26DETT (2.6L) 11mm has been engineered with increased „„ Dual chamfered ends 20002444 Nissan SR20DET (2.0L) 12mm „„ Increased performance seat pressure along with higher lift

High Performance Valve Train High RPM Valve Spring Sets

Part No. Application

20000164 Mitsubishi Evo VII-IX 4G63 High RPM Single Valve Spring set (16)

20000166 High RPM Single Valve Spring set (16) Subaru WRX STI EJ25 (2.5L) EJ20 (2.0L)

20000163 High RPM Single Valve Spring set (24) Nissan VQ35 (3.5L)

20000168 High RPM Single Valve Spring set (16) Nissan SR20DET (2.0L)

20000169 High RPM Single Valve Spring set (24) Nissan RB26 (2.6L)

20000167 High RPM Single Valve Spring set (16) BMW MINI Cooper/Cooper S (1.6L)

Mitsubishi 4G63 Subaru EJ20/EJ25 Nissan VQ35DE

Valve Train Specification(L1=Install Height, F1=Force @ L1, L2=Max Lift, F2=Force @ Max Lift)

Part No. Application Free Height L1 mm F1 N F1 lbs L2 mm F2 N F2 lbs Max Lift Coil Bind

20000167 Mini 1.6 Tritec 48.85 43.0 348 80 33.0 944 212 11.0 30.7

20000164 Mitsubishi EVO 7-9 47.00 38.1 381 85 26.1 900 202 12.0 24.3

20000169 Nissan RB26 49.30 41.9 359 81 29.9 941 212 12.0 28.4

20000168 Nissan SR20 46.00 39.0 365 82 27.5 964 217 11.5 25.4

20000163 Nissan VQ35DE 46.00 38.0 289 65 24.5 775 175 13.5 22.9

20000166 Subaru EJ 2.0/2.5 42.00 36.0 275 62 25.0 780 175 11.0 23.2

KK3813 Mitsubishi EVO 7-9 50.00 38.1 512 115 26.9 1268 285 12.0 25.7

20002550 Nissan VQ35DE 47.00 38.0 378 85 23.9 1183 266 14.1 22.6

KK3829 Subaru EJ 2.0/2.5 46.10 36.0 356 80 22.1 1019 229 13.9 20.8

All dimensions are in millimetres unless otherwise specified

21 Induction / Fuel

VQ35 Twin Plenum Intake Induction / Fuel Manifold Part No. Application

The Cosworth Twin Plenum Inlet 20000063 Nissan VQ35DE (3.5L) Twin Plenum Intake Manifold with carbon plenum covers Manifold for the Nissan VQ35DE KK3905 Nissan VQ35DE (3.5L) High Volume Fuel Rail kit has been designed to enhance mid-range and high RPM power. It features increased plenum volume for improved high RPM power while torque enhancing velocity stacks improve mid-range power. With performance derived from countless hours of development including computational fluid dynamics, the Cosworth Twin Plenum Inlet Manifold is perfect for both normally aspirated and forced induction applications. Cast from lightweight aluminium alloy with carbon fibre end caps and includes all required mounting hardware. Will fit with original strut tower brace. Can be used with the factory fuel rail system or the Cosworth High Volume Fuel Rail kit.

VQ35 High Volume Fuel Rail System

The original factory VQ35DE fuel rail arrangement is limited in performance. The Cosworth VQ35 High Volume Fuel System features high volume anodized fuel rails, with o-ringed fittings and is fully configurable for various applications. Each system includes sleeved high pressure fuel lines along with a CNC machined distribution block that includes an additional port for various sensors. The Cosworth High Volume Fuel Rail System can be used with original or various aftermarket injectors.

22 Induction / Fuel Disclaimer

The products in this catalogue require professional installation to ensure correct Induction / Fuel operation. Cosworth will not accept responsibility for damage to vehicles as a Part No. Application result of improper installation of our products. 20000063 Nissan VQ35DE (3.5L) Twin Plenum Intake Manifold with carbon plenum covers KK3905 Nissan VQ35DE (3.5L) High Volume Fuel Rail kit The performance and power gained from installing products from this catalogue may place vehicles within an “off road use only” category in certain counties and states around the world. Cosworth will not accept responsibility for any restrictions placed on vehicles.

Product Disclaimer: A vehicle modified with Cosworth competition and or racing performance products will not meet the legal requirements for operation on public roads and highways. It is the purchaser’s responsibility to check and comply with all local, state and federal laws prior to operating vehicle. Installation and use of performance products may also affect/ void vehicle warranty and insurance policy.

Warranty: In general, Cosworth Performance Parts carry no warranty. Cosworth Ltd and Cosworth LLC shall not be liable for direct, indirect, incidental or consequential damage or injury to persons or property that might be claimed as a result from the installation, improper installation and failure of part including claims for delay, loss of profits or labour. There are no warranties expressed or implied.

SOME PRODUCTS MAY NOT BE LEGAL FOR SALE OR USE ON POLLUTION CONTROLLED MOTOR VEHICLES OPERATING IN THE STATE OF CALIFORNIA

23 © Copyright 2007, Cosworth Ltd / Cosworth LLC - v1.1

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